Mechanical integration of buttons for piezo-electric actuators

ABSTRACT

A piezo-electric actuator on the side of a mobile device will enable pressure exerted by the user to be sensed at the conventional button locations, while providing a haptic feedback. Unfortunately, mechanical integration of piezo-electric actuators at the side of a mobile device is challenging. A mobile device in accordance with the present disclosure comprises a PCB; an outer frame surrounding the PCB; and a switch. The switch comprises: a first piezo-electric actuator configured to generate a first actuator voltage signal in response to a first force applied by a user, and to generate a first haptic feedback to the user in response to a first haptic voltage signal transmitted from the controller thereto; and a first virtual button in the outer frame configured to transmit the first force to the first piezo-electric actuator, and to transmit the first haptic feedback to the user.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/986,175 filed Mar. 6, 2020, which is incorporatedherein by reference.

TECHNICAL FIELD

The present disclosure relates to the replacement of conventionalelectronic buttons with piezo-electric actuators, and in particular tothe mechanical integration of buttons for piezo-electric actuators inmobile devices.

BACKGROUND

Using a piezo-electric actuator on the side of a mobile device not onlyenables the device's control system to sense the pressure exerted by theuser at the location where buttons were traditionally positioned, butalso provides a haptic feedback to the user that the “button” was“pressed”. However, mechanical integration of piezo-electric actuatortechnology may come with a fair amount of challenges.

An object of the present disclosure is to replace physical buttons onmobile devices, e.g. smartphones and tablets, with piezo-electricactuators controlled by integrated circuits.

SUMMARY

Accordingly, a first apparatus includes a mobile device comprising: aPCB including a controller; an outer frame comprised of a hard-plasticand/or metallic material surrounding the PCB; a switch. The switchcomprising: a first piezo-electric actuator configured to generate afirst actuator voltage signal in response to a first force appliedthereto by a user, and to generate a first haptic feedback to the userin response to a first haptic voltage signal transmitted from thecontroller thereto; and a first virtual button in the outer frameconfigured to transmit the first force from the user to the firstpiezo-electric actuator, and to transmit the first haptic feedback fromthe first piezo-electric actuator to the user.

BRIEF DESCRIPTION OF THE DRAWINGS

Some example embodiments will be described in greater detail withreference to the accompanying drawings, wherein:

FIG. 1 is a partially sectioned top view in accordance with an examplemechanical integration of a piezo-electric actuator in the side of amobile device of the present disclosure;

FIG. 2 is a partially sectioned side view of the device of FIG. 1;

FIG. 3 is a top view of the device of FIG. 1;

FIG. 4 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 5 is an isometric view of the device of FIG. 4;

FIG. 6 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 7 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 8 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 9 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 10 is a partially sectioned isometric view of the device of FIG. 9;

FIG. 11 is an exploded view of the device of FIG. 9;

FIG. 12 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 13 is a partially section side view of the device of FIG. 12;

FIG. 14 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure

FIG. 15 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 16 is a partially sectioned side view of the device of FIG. 15;

FIG. 17 is a top view of the device of FIG. 15;

FIG. 18 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 19 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure

FIG. 20 is a partially sectioned side view of the device of FIG. 19;

FIG. 21 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 22 is a partially sectioned side view of the device of FIG. 21;

FIG. 23 is a top view of the button structure of the device of FIG. 21;

FIG. 24 is an isometric view of the device of FIG. 21;

FIG. 25 is a partially sectioned top view in accordance with anotherexample of a mechanical integration of a piezo-electric actuator in theside of a mobile device of the present disclosure;

FIG. 26 is a partially sectioned side view of the device of FIG. 25;

FIG. 27 is an isometric view in accordance with another example of amechanical integration of a piezo-electric actuator in the side of amobile device of the present disclosure

FIG. 28 is an exploded view of the device of FIG. 27;

FIG. 29 is a side view of the device of FIG. 27;

FIG. 30 is an isometric view of the outer frame of the device of FIG.27; and

FIG. 31 is an isometric view of the outer frame of the device of FIG. 27with the piezo-electric actuators installed.

DETAILED DESCRIPTION

While the present teachings are described in conjunction with variousembodiments and examples, it is not intended that the present teachingsbe limited to such embodiments. On the contrary, the present teachingsencompass various alternatives and equivalents, as will be appreciatedby those of skill in the art.

With reference to FIGS. 1 to 3, a mobile device 1, e.g. a smart phone ortablet, includes an outer frame 2 with at least one opening 3 extendingtherethrough and at least one hinge 4, defining at least one virtualbutton 5 therein. Each hinge 4 may be formed by a thinned section of theouter frame 2 extending only partially through the outer frame 2, e.g. aliving hinge. The opening 3 may extend through the entire thickness andheight of the outer frame 2 forming a cantilevered structure, e.g. thevirtual button 5. The opening 3 may be filled and sealed from externaldirt and moisture, with a resilient member 6, e.g. an elastic material,such as an elastomer thermoplastic, to weaken the outer frame 2 of themobile device 1, i.e. to locally lower the rigidity and form the virtualbutton 5, thereby enabling a small displacement of each of the virtualbuttons 5 to activate one or more piezo-electric actuators 10 forming anelectrical switch and/or other electronic control. A trough 7 formed inthe inner wall of the outer frame 2 on one side of the virtual button 5as a result of forming the thinned section of the hinge 4 may also befilled with the same material as the resilient member 6 or some othersuitable elastic material. The resilient member 6 may be inserted ineach of the openings 3 and in the trough 7 by various methods, such aspouring, over molding, etc., and may fill the opening 3 and in thetrough 7 and adhere to the outer frame 2, in particular edges of thevirtual buttons 5, enabling an ingress protection and lower rigidity.

The mobile device 1 may include two virtual buttons 5 each with one ofthe hinges 4, e.g. thinned sections, but sharing the same opening 3 andthe same resilient member 6 attached at each outer end and extendingtherebetween. With particular reference to FIG. 4, the hinges 4, i.e.the thinned sections, may form a living hinge, whereas the resilientmember 6 in the opening 3 may provide limited local deformation, e.g.approximately 0.02 mm-0.5 mm for 5 N force and a sidewall rigidity of 10N/mm to 250 N/mm, but preferably 0.07 mm to 0.5 mm deflection for 10N/mm to 70 N/mm rigidity, while maintaining a seal, e.g. hermetic or atleast partially water proof with the outer frame 2. The thickness of theouter frame 2 thins from a normal thickness, e.g. of 3 mm-6 mm, to areduced thickness at the virtual buttons 5, e.g. to 25% to 50% of theoriginal thickness or to 0.5 mm to 2 mm, preferably 1 mm to 2 mm. Eachtrough 7 may include an even thinner thickness of ¼ to ½ of the rest ofthe virtual button 5 or ⅛ to 1/20 the original thickness, such as 0.25mm to 0.75 mm, preferably 0.25 mm to 0.4 mm. There may be cavities 9within the outer frame 2, similar to FIG. 21, to make room for thepiezo-electric actuators 10, in that case, the outer frame 2 may have alocal thickness of 2 mm-4 mm, from the exterior surface to cavity 9.

The outer frame 2 may also include one or more pedestals 8 extendingfrom an outer wall of the outer frame 2, i.e. the virtual buttons 5,into one or more cavities 9 in the mobile device 1, e.g. a hollowsection in the outer frame 2, between the outer frame 2 and an innerframe 12 or between the outer frame 2 and a PCB 16, which may be mountedon the inner frame 12 or the outer frame 2. Each pedestal 8 may thenextend into contact with one side of one of the piezo-electric actuators10 disposed in the cavity 9. The high rigidity of the outer frame 2 maybe achieved once the virtual button 5 is sufficiently pressed to enterin contact with a hard stop 11, which extends from an inner structure,e.g. the inner frame 12, the PCB 16 or the outer frame 2, into thecavity 9 to within a small distance, i.e. proximate, to the virtualbutton 5 with a gap therebetween, thereby transferring the force to theinner frame 12, the PCB 16 or the outer frame 2 instead of the weakenedsections of the outer frame 2, e.g. the opening 3 and the hinge 4.Accordingly, the virtual button 5 may only be pushed the distance of thegap, after which a first abutting surface on the virtual button 5contacts a second abutting surface on the hard stop 11, therebytransferring any additional force to the inner frame 12, the outer frame2 or the PCB 16 and preventing any further force from damaging thepiezo-electric actuators 10. In FIG. 1, the hard stops 11 extendadjacent to the resilient member 6 in the opening 3, remote from thehinges 4, e.g. the thinned sections, which is the location of thegreatest deflection of the buttons 5. A single opening 3 with theresilient member 6 may be shared by two adjacent buttons 5, while eachbutton 5 includes one hinge 4, e.g. one thinned section or living hinge.

The piezo-electric actuator 10 may comprise a TDK PowerHap™ 1204H018V060with a length of approximately 12 mm, and a width of approximately 4 mm,and a thickness of approximately 1.8 mm; however, any suitablepiezo-electric actuator 10 may be used. The thickness of the outer frame2 forming the virtual buttons 5, e.g. 0.3 mm to 1 mm, may have asufficient area to bond to a top display 13 and a back cover 14 providedon the mobile device 1. The outer frame 2 may be formed in one piece,e.g. monolithic, with the back cover 14 or the outer frame 2 and theback cover 14 may be separate pieces. An additional slot may have to becut along the side of the virtual button 5 to separate the virtualbutton 5 from the back cover 14, when the outer frame 2 and the backcover 14 comprise a single structure. The resilient members 6 and theresilient material in the troughs 7, may provide a continuous surfacewith the outer surface of the outer frame 2 to contact anadhesive/seal/gasket. Since the virtual buttons 5 may be very thin,especially at the hinge 4, there is little surface to apply adhesive tofix the top display 13 and the back cover 14; accordingly, the adhesivehas the role to seal the outer frame 2 to the top display 13 and theback cover 14 from water and dust ingress.

A PCB flex connector 15 may be used to connect the piezo-electricactuator 10 to a controller of the mobile device 1 for exchanging anactuator voltage signal generated by the piezo-electric actuator 10, inresponse to a force applied to the virtual button 5, to the controller,and a haptic voltage signal to the piezo-electric actuator 10 to providethe haptic feedback to the user. The controller may be a separate chipmounted on and electrically connected to the PCB 16 or integrated in thePCB 16. The side of the mobile device 1, e.g. the outer surface of theouter frame 2 and the virtual buttons 5 may remain simple andcontinuous; however, color variation of the resilient members 6 arepossible to clearly delineate the virtual buttons 5. With reference toFIG. 3, the resilient members 6 are the two thin bands on the left andright of the volume control virtual buttons 5. Accordingly, a forceapplied by the user to the side of the mobile device 1 to the virtualbutton 5 in the outer frame 2, i.e. perpendicular to the display 13 andthe back cover 14, results in the transmission of the force from theuser to the piezo-electric actuator 10, and in the transmission of thehaptic feedback from the piezo-electric actuator 10 to the user.

In an alternate example, illustrated in FIGS. 5-7, each virtual button 5may include their own opening 3, e.g. at an outer edge thereof, with theresilient member 6 therein, and their own hinge 4, e.g. thinned sectionforming a living hinge, with the elastic material therein. As above, thehard stops 11 extend into the cavity 9 on an opposite side to the hinge4 proximate to the virtual buttons 5. The hard stops 11 may extend froman inner structure, such as the inner section of the outer frame 2, theinner frame 12 or from an edge of the PCB 16 adjacent to the resilientmembers 6 in the openings 3.

The virtual buttons 5 of FIG. 5 include a pedestal 8, whereas thevirtual buttons 5 in FIG. 6 do not. However, with reference to FIG. 7,instead of or in addition to pedestals 8, a gap filler material 30 maybe positioned between the virtual buttons 5 and the piezo-electricactuators 10 to ensure that the piezo-electric actuators 10 are locatedwithin the cavities 9 the correct distance from the inside wall of thevirtual buttons 5. The gap filler material 20 may comprise an adhesivematerial or a combination of adhesive material and non-adhesive filler.A small channel 31 may be provided in the inside wall of the outer frame2 to ensure enough space is provided for the gap filler material 30.

In an alternate example of the mobile device 1, illustrated in FIG. 8,each virtual button 5′ may include two openings 3, one at each sidethereof with a resilient member 6 therein, whereby one or both of theresilient members 6 forms a hinge. Adjacent virtual buttons 5′ may sharea common opening 3 with the single resilient member 6. As above, thehard stops 11 extend from the outer frame 2 on an opposite side of thecavities 9, the internal frame 12 or the edge of the PCB 16 to proximatethe virtual buttons 5′, adjacent to all of the resilient members 6 inthe openings 3. The virtual button 5′ may include sections of the outerframe 2 removed when the openings 3 are formed, sections comprising thesame material as the outer frame 2 for continuity, some other materialconfigured to look like the outer frame 2, or some other materialproviding a contrast in color and style to the outer frame 2.

With reference to FIGS. 9 to 11, in all of the aforementionedembodiments, the piezo-electric actuator 10 may be mounted within aprotective housing 100 to ensure too large a force is not transmitted tothe piezo-electric actuators 10, i.e. a force greater than what thepiezo-electric actuators 10 can tolerate without substantial damage.

The housing 100 may comprise a main cover 101, including a base 102 andone or more vertical sections or walls 103 perpendicular to the base102, e.g. four walls forming a rectangular body. The walls 103 may beconfigured to surround the piezo-electric actuator 1 forming an openingat one side providing access to a contact side of the piezo-electricactuator 10. The housing 100 may also include a pusher plate 105covering the opening to the main cover 101, and including a centralportion 106 in contact, e.g. connected with double sided tape 104, withthe contact side of the piezo-electric actuator 10, and outer portions107 at the edges of the pusher plate 105 space apart from outer freeends of the one or more walls 103 by a desired gap 108. Accordingly, theouter portions 107 form a first abutting surface, and the outer freeends of the one or more walls 103 form a second abutting surfaceproviding a hard stop for the piezo-electric actuator 10 after thepusher plate 105 has been pushed as far as the gap 108, therebyprotecting the piezo-electric actuator 10 from substantial damage fromthe application of excess force. The pusher plate 105 may also include araised section or bump 109 extending outwardly from the central portion106 for engaging one of the virtual buttons 5, as hereinbeforedescribed. Accordingly, the virtual button 5 may only be pushed thedistance of the gap, after which the first abutting surface contacts thesecond abutting surface, thereby transferring any additional force tohousing and/or the inner frame 12 or PCB 16 and preventing any furtherforce from damaging the piezo-electric actuators 10.

The housing 100 may also provide compensation for the wide variabilityin length of the piezo-electric actuators 10 by using moveablecomponents or by filling gaps between the piezo-electric actuator 10 andthe base 102 of the housing 100 with gap filling adhesive 110. Byencapsulating the piezo-electric actuator 10 in a cartridge, i.e. thehousing 100, the length of the housing 100 may be precisely controlledand a hard stop may be integrated independent of the frame of the mobiledevice 1. This would simplify the manufacturing process of the smartdevice 1 by eliminating two of the challenges in the design andintegration of the piezo-electric actuator 10.

With reference to FIGS. 12 and 13, a pair of encapsulated piezo-electricactuators 10 are disposed in a smart device, similar to mobile device 1of FIGS. 1-4, including the outer frame 2 and the virtual buttons 5,which include the shared opening 3 with the resilient member 6 therein,and the living hinges 4 on opposite sides thereof formed by the thinnedareas 4 with the trough 7, which may also be filled with elasticmaterial. The piezo-electric actuators 10 are encapsulated in thehousing 100, and are positioned between the inner frame 12 or the PCB 16and the outer frame 2 in the cavity 9. The virtual buttons 5 may includethe pedestals 8 for contacting the pusher plate 105, and in particularthe bump 109, but are not necessary, depending on the application, e.g.when there is no available space.

With reference to FIG. 14, a pair of encapsulated piezo-electricactuators 10 are disposed in a smart device, similar to mobile device 1of FIG. 8, including the outer frame 2 and the virtual buttons 5, whichinclude the shared opening 3 with the resilient member 6, and theadditional openings 3 on opposite sides of each button 5, both filledwith one of the resilient members 6. One or both of the resilientmembers 6 forming a hinge. The piezo-electric actuators 10 areencapsulated in the housing 100, and are positioned between the innerframe 12 or the PCB 16 and the outer frame 2 in the cavity 9. Thevirtual buttons 5 may include the pedestals 8 for contacting the pusherplate 105, and in particular the bump 109, but are not necessary,depending on the application, e.g. when there is no available space.

With reference to FIGS. 15 to 17, a pair of encapsulated piezo-electricactuators 10 are disposed in the mobile device 1, including the outerframe 2 and virtual buttons 205. Each piezo-electric actuator 10 isencapsulated in one of the housings 100, and may be positioned betweenthe inner frame 12 or the PCB 16 and the outer frame 2 in one orseparate cavities 9 or within the cavities 9 in the outer frame 2. Thevirtual buttons 205 are formed by thinning the outer frame 2 to athickness, such as 0.25 mm to 0.75 mm, e.g. ⅛ to 1/20 the originalthickness of 3 mm-4 mm, that enables a minor deflection, see FIG. 17,e.g. 0.02 mm to 0.5 mm at a 5 N force, and a sidewall rigidity of 10N/mm to 250 N/mm, preferably 0.07 mm to 0.5 mm deflection for 10 N/mm to70 N/mm rigidity. Living hinges 204 are formed at the edges of thevirtual buttons 205, where the virtual buttons 205 meet the thickerouter frame 2. The thinned section of the virtual buttons 205 mayinclude a pedestal 208 which extends from the outer wall of the outerframe 2 into contact with the piezo-electric actuator 10, and inparticular to the pusher plate 105, and even more specifically to thebump 109 on the pusher plate 105 for activating the piezo-electricactuator 10 and receiving haptic feedback therefrom.

With reference to FIG. 18, a pair of encapsulated piezo-electricactuators 10 are disposed in the smart device 201, including the outerframe 2 and the virtual buttons 205. Each piezo-electric actuator 10 maybe encapsulated in one of the housings 100, and may be positionedbetween the inner frame 12 or the PCB 16 and the outer frame 2 in asingle cavity 9 or within a single cavity 9 in the outer frame 2. Theplurality of virtual buttons 205 may be constructed of a single thinnedsection of the outer frame 2. A pivot structure 210 extending from theinner frame 12 or the PCB 16 may be positioned in the cavity 9 betweenthe encapsulated piezo-electric actuators 10 to provide a pivot pointand a hard stop for the individual virtual buttons 205 on either sidethereof. The virtual buttons 205 are formed by thinning the outer frame2 to a thickness such as 0.25 mm to 0.75 mm, e.g. ⅛ to 1/20 the originalthickness of 3 mm to 4 mm, that enables a minor deflection, e.g. 0.02 mmto 0.5 mm at a 5 N force a sidewall rigidity of 10 N/mm to 250 N/mm,preferably 0.07 mm to 0.5 mm deflection for 10 N/mm to 70 N/mm rigidity.The thinned section of the virtual buttons 205 may include a pedestal208 which extends from the outer wall of the outer frame 2 into contactwith the piezo-electric actuator 10, and in particular to the pusherplate 105, and even more specifically to the bump 109 on the pusherplate 105 for activating the piezo-electric actuator 10 and receivinghaptic feedback therefrom.

Another example of an integrated mechanical button for the mobile device1 is illustrated in FIGS. 19 and 20, and includes a thin membrane, e.g.plastic or glass, fascia 61 that covers virtual buttons 65 in the formof push blocks, which extend through holes 63 in the outer frame 2 intocontact with the piezo-electric actuators 10. The virtual buttons 65,e.g. the push blocks, may be comprised of a light transparent material,and used as a light pipe to transmit light from an internal light sourceto the glass fascia 61 to illuminate the functionality of the virtualbuttons 65, when the thin glass of the fascia 61 is used as a stencil inconjunction therewith. The virtual buttons 65, e.g. the push blocks, mayalso include hard stops 66 to limit the amount of force transmitted tothe piezo-electric actuators 10. The hard stops 66 may be in the form ofa first abutting surface 67, e.g. a shoulder, on the virtual buttons 65,e.g. the push block, and a second abutting surface 68, e.g. a ledge, onthe outer frame 62 with a gap therebetween. Accordingly, the virtualbutton 65 may only be pushed the distance of the gap, after which thefirst abutting surface 67 contacts the second abutting surface 68,thereby transferring any additional force to the outer frame 62 andpreventing any further force from damaging the piezo-electric actuators10.

Another feature of the example in FIGS. 19 and 20, was to use existingcomponents, such as the PCB 16, in a manner that would allow theadjustment of a preload made to the piezo-electric actuators 10 tocompensate for the large tolerance of their length. For example, one ormore of the piezo-electric actuators 10 may be mounted in the cavity 9,and the PCB 16 may be positioned against an inner side of thepiezo-electric actuators 10 providing a pre-loading force thereon. ThePCB 16 may then be fixed to the inner frame 12 with an adhesive or amechanical fastener 71, e.g. screw or bolt, providing a permanentpre-load to each of the piezo-electric actuators 10.

Another example of the mobile device 1 is illustrated in FIGS. 21-23,and includes a button structure 81 that would move in relationship tothe outer frame 2 of the smart device 1, but unlike a traditionalmechanical button, the displacement would be very small, and a multitudeof haptic feedback could be created. The ingress protection challengewould be insured by seals 82 between the button structure 81 and theouter frame 2. Special attention could be taken to minimize theappearance of any gap between the button structure 81 and the outerframe 2.

The button structure 81 may comprise a plurality of interconnectedvirtual buttons 85 extending through holes 83 in the outer frame 2 intocontact with a respective one of a plurality of piezo-electric actuators10, mounted inside respective cavities 9 or a single cavity 9 in oradjacent to the outer frame 2. The button structure 81 may include oneor more extensions 86 extending through the holes 83 into contact withrespective piezo-electric actuators 10, and one or more projections 87(tenon) extending into the outer frame 2 in between adjacent extensions86, for fitting, e.g. frictionally, into a complementary groove 88(mortise) provided in the outer frame 2 for increasing the bonding areaof the button structure 81 to the outer frame 2. The projection 87 andthe groove 88 may extend partially through the outer frame or theprojection 87 and the groove 88 may extend all the way through the outerframe 2.

With particular reference to FIG. 23, one or both sides of eachprojection 87 may provide a pivot points or a hinge 84 for the virtualbuttons 85. The hinges 84 between the projection 87 and the extensions86 may be made by providing a relatively thinned section between eachextension 86 and the projection 87, which is thinner than the rest ofthe button structure 81, forming troughs 89 which may be filled withelastic material, providing living hinges to facilitatemovement/rotation of the virtual buttons 85.

The button structure 81 may also include a first abutting surfacecomprising shoulders on either side of the extensions 86 and/orprojections 87 for abutting a second abutting surface formed by ledgesin the outer frame 2 on either side of the stepped openings that receivethe extensions 86 and the projection 87. Accordingly, the virtual button5 may only be pushed the distance of a gap between the first abuttingsurface and the second abutting surface, after which the first abuttingsurface contacts the second abutting surface, thereby transferring anyadditional force to the outer frame 2 and preventing any further forcefrom damaging the piezo-electric actuators 10. The seals 82 may bedisposed in the first abutting surface and/or the second abuttingsurface, e.g. in the shoulders of the extensions 86 and/or theprojections 87 and in the ledges in the outer frame 2.

Gap filling adhesive 91 may be provided between the piezo-electricactuators 10 and the outer frame 2 and/or the inner frame 12 tocompensate for loose tolerances of the piezo-electric actuators 10.

FIG. 24 illustrates a variant of this concept in which the buttonstructure 81 shares the same gap as the back cover 14 and the frontdisplay 13, i.e. the buttons 85 are the same thickness as the outerframe 2, leaving only two small vertical gaps between the buttonstructure 81 and the outer frame 2, which could also be filled by anelastic material, as hereinbefore described.

In an alternate example, illustrated in FIGS. 25 and 26, all the otherelements may be the same, but each cavity 9 may be formed between theouter frame 2 and the inner frame 12 or the PCB 16, and may be comprisedof a single opening or cavity 9 for a plurality of piezo-electricactuators 10. Accordingly, the inner side of the piezo-electricactuators 10 are mounted against the inner frame 12 or the PCB 16, whilethe outer side of the piezo-electric actuators 10 are in contact withthe extensions 86. In some embodiments, the projections 87 may notextend the entire width through the outer frame 2, i.e. extend onlypartially through the outer frame 2, thereby minimizing the points ofingress into the mobile device 1. Accordingly, the groove 88 in theouter frame 2 only extends partially into the outer frame.

In some embodiment, the button structure 81 may have a differentthickness than the outer frame 2, namely the button structure 81 may bethinner than the thickness of the outer frame 2, whereby the virtualbuttons 85 fit in the outer frame 2 and are totally surrounded by theouter frame 2 creating additional gaps that need to be sealed, as above.

Another embodiment of the mobile device 1 includes a display 52, e.g.transparent material, such as glass or plexiglass, that may be flexibleenough to transmit the haptic feedback generated by the piezo-electricactuator 10. The example of FIGS. 27-31 includes the display 52, whichincludes elongated curved sections extending from a side of a flat maindisplay section 53 around at least a portion of a side of the outerframe 2, up to the entire side of the outer frame 2, forming one or moredifferent individual curved tabs representing virtual buttons 55.Located under the virtual buttons 55, the piezo-electric actuators 10are separated by a small gap 56 between the display 52, i.e. the virtualbuttons 55, and the outer frame 2 to allow for a small displacement ofthe virtual buttons 55, enough for the piezo-electric actuator 10 tosense the input from the user and the piezo-electric actuator 10 totransmit the haptic feedback back to the user. However, a hard stop isformed by the edge of the virtual buttons 55, i.e. a first abuttingsurface, contacting the outer frame 2, i.e. a second abutting surface,as soon as the gap 56 is traversed by the virtual buttons 55 to protectthe piezo-electric actuators 10. Accordingly, the virtual buttons 55 mayonly be pushed the distance of the gap 56 between the first abuttingsurface and the second abutting surface, after which the first abuttingsurface contacts the second abutting surface, thereby transferring anyadditional force to the outer frame 2 and preventing any further forcefrom damaging the piezo-electric actuators 10. In this case, the sensingcould also be captured by the display 52, when the display 52 comprisesa touch-sensitive display. A force transmitting push block 58 comprisinga rigid material, e.g. plastic, may be provided between the virtualbuttons 55 and the piezo-electric actuator 10 to transmit the forcestherebetween.

With reference to FIGS. 30 and 31, the piezo-electric actuators 10 maybe mounted on the outer frame 2 at an acute angle to the vertical sidewall, e.g. about 15°-75°, preferably about 20° to 45°, and to thedisplay 52 and the back cover 14 via an angled support 59. At least oneflex PCB connector 15 may be used to connect the piezo-electricactuators 10 to a controller on the PCB 16 of the mobile device 1 forexchanging an actuator voltage signal to the controller and a hapticvoltage signal to the piezo-electric actuator 10 to provide the hapticfeedback to the user.

The term controller or processor may include a computer processorincluding computer hardware and computer software executable thereonalong with suitable memory for storing the computer software. The termcircuit may include dedicated hardware or hardware in associated withsoftware executable thereon.

As used in this application, the term “circuitry” may refer to one ormore or all of the following:

(a) hardware-only circuit implementations (such as implementations inonly analog and/or digital circuitry);

(b) combinations of hardware circuits and software, such as (asapplicable):

(i) a combination of analog and/or digital hardware circuit(s) withsoftware/firmware and

(ii) any portions of hardware processor(s) with software (includingdigital signal processor(s)), software, and memory(ies) that worktogether to cause an apparatus, such as a mobile phone or server, toperform various functions); and

(c) hardware circuit(s) and or processor(s), such as a microprocessor(s)or a portion of a microprocessor(s), that requires software (e.g.,firmware) for operation, but the software may not be present when it isnot needed for operation.”

This definition of circuitry applies to all uses of this term in thisapplication, including in any claims. As a further example, as used inthis application, the term circuitry also covers an implementation ofmerely a hardware circuit or processor (or multiple processors) orportion of a hardware circuit or processor and its (or their)accompanying software and/or firmware. The term circuitry also covers,for example and if applicable to the particular claim element, abaseband integrated circuit or processor integrated circuit for a mobiledevice or a similar integrated circuit in server, a cellular networkdevice, or other computing or network device.

The foregoing description of one or more example embodiments has beenpresented for the purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed. Many modifications and variations are possible in light ofthe above teaching. It is intended that the scope of the disclosure belimited not by this detailed description.

We claim:
 1. A mobile device comprising: a PCB including a controller;an outer frame surrounding the PCB; a switch comprising: a firstpiezo-electric actuator configured to generate a first actuator voltagesignal in response to a first force applied thereto by a user, and togenerate a first haptic feedback to the user in response to a firsthaptic voltage signal transmitted from the controller thereto; and afirst virtual button at a side of the mobile device in the outer frameconfigured to transmit the first force from the user to the firstpiezo-electric actuator, and to transmit the first haptic feedback fromthe first piezo-electric actuator to the user.
 2. The mobile deviceaccording to claim 1, wherein the first virtual button comprises: aresilient member in an opening in the outer frame at a first end of thefirst virtual button; and a first living hinge comprised of a firstthinned section of the outer frame at an opposite second end of thefirst virtual button; wherein the first virtual button comprises a firstcantilevered section of the outer frame, thicker than the first thinnedsection, extending between the first living hinge and the resilientmember.
 3. The mobile device according to claim 2, further comprising: asecond piezo-electric actuator configured to generate a second actuatorvoltage signal in response to a second force applied thereto by theuser, and to generate a second haptic feedback to the user in responseto a second haptic voltage signal transmitted from the controllerthereto; and a second virtual button in the outer frame configured totransmit the second force from the user to the second piezo-electricactuator, and to transmit the second haptic feedback from the secondpiezo-electric actuator to the user; wherein the second virtual buttonincludes a second living hinge comprised of a second thinned section ofthe outer frame at an opposite second end of the second virtual button;wherein the second virtual button comprises a second cantileveredsection of the outer frame, thicker than the second thinned section,extending between the second living hinge and the resilient member; andwherein the resilient member is connected to both the first virtualbutton and the second virtual button.
 4. The mobile device according toclaim 1, wherein the first virtual button comprises: a first resilientmember in a first opening in the outer frame at a first end of the firstvirtual button; a second resilient member in a second opening in theouter frame at an opposite second end of the first virtual button; and afirst button section extending between the first resilient member andthe second resilient member.
 5. The mobile device according to claim 4,further comprising: a second piezo-electric actuator configured togenerate a second actuator voltage signal in response to a second forceapplied thereto by the user, and to generate a second haptic feedback tothe user in response to a second haptic voltage signal transmitted fromthe controller thereto; and a second virtual button in the outer frameconfigured to transmit the second force from the user to the secondpiezo-electric actuator, and to transmit the second haptic feedback fromthe second piezo-electric actuator to the user; wherein the secondvirtual button includes a third resilient member in a third opening inthe outer frame at an opposite second end of the second virtual button,and a second button section extending between the third resilient memberand the second resilient member.
 6. The mobile device according to claim1, wherein the first virtual button comprises: a first living hingecomprised of a first thinned section of the outer frame at a first endof the first virtual button; and a second living hinge comprised of asecond thinned section of the outer frame at an opposite second end ofthe first virtual button; and a first button section extending betweenthe first living hinge and the second living hinge.
 7. The mobile deviceaccording to claim 6, further comprising: a second piezo-electricactuator configured to generate a second actuator voltage signal inresponse to a second force applied thereto by the user, and to generatea second haptic feedback to the user in response to a second hapticvoltage signal transmitted from the controller thereto; and a secondvirtual button in the outer frame configured to transmit the secondforce from the user to the second piezo-electric actuator, and totransmit the second haptic feedback from the second piezo-electricactuator to the user; wherein the second virtual button comprises: athird living hinge comprised of a third thinned section of the outerframe; a fourth living hinge comprised of a fourth thinned section ofthe outer frame; a second button section extending between the thirdliving hinge and the fourth living hinge; and a pivot member extendingfrom an inner frame or the PCB adjacent to the second living hinge andthe third living hinge; wherein the second living hinge and the thirdliving hinge are connected together and configured to pivot about thepivot member.
 8. The mobile device according to claim 1, wherein thefirst virtual button comprises: a first push block extending through afirst hole in the outer frame for transmitting the first force from theuser and receiving the first haptic feedback from the firstpiezo-electric actuator; and seals between the first block and the outerframe.
 9. The mobile device according to claim 1, wherein the firstvirtual button comprises: a first extension extending though a firsthole in the outer frame into contact with the first piezo-electricactuator; a projection extending into a complementary groove provided inthe outer frame; and a first living hinge comprised of a first thinnedsection between the first extension and the projection.
 10. The mobiledevice according to claim 9, further comprising: a second piezo-electricactuator configured to generate a second actuator voltage signal inresponse to a second force applied thereto by the user, and to generatea second haptic feedback to the user in response to a second hapticvoltage signal transmitted from the controller thereto; and a secondvirtual button in the outer frame configured to transmit the secondforce from the user to the second piezo-electric actuator, and totransmit the second haptic feedback from the second piezo-electricactuator to the user; wherein the second virtual button comprises: asecond extension extending though a second hole in the outer frame intocontact with the second piezo-electric actuator; and a second livinghinge comprised of a second thinned section between the second extensionand the projection.
 11. The mobile device according to claim 10, furthercomprising: a first abutting surface comprised of shoulders formedaround the first extension; and a second abutting surface formed byledges in the outer frame on either side of the first hole; therebyenabling a deflection of the first virtual button sufficient to activatethe first piezo-electric actuator, while preventing damage to the firstpiezo-electric actuator.
 12. The mobile device according to claim 1,further comprising: a top display mounted on one side of the outerframe; wherein the first virtual button comprises: a curved tabextending from the top display at least partially over the outer frameat the side of the mobile device; and a first push block disposedbeneath the curved tab and extending through a first hole in the outerframe for transmitting the first force from the user and receiving thefirst haptic feedback from the first piezo-electric actuator; wherein anapplication of the first force on the curved tab activates the firstpiezo-electric actuator.
 13. The mobile device according to claim 12,wherein the first piezo-electric actuator is disposed at an acute angleto the outer frame.
 14. The mobile device according to any one of claim1, further comprising a hard stop extending from an inner structure orthe PCB to proximate the first virtual button with a gap therebetweenenabling a deflection of the first virtual button sufficient to activatethe first piezo-electric actuator, while preventing substantial damageto the first piezo-electric actuator.
 15. The mobile device according toany one of claims claim 1, further comprising: a main housing comprisingone or more walls adjacent to the first piezo-electric actuator, and abase connected to a first side of the first piezo-electric actuator; anda pusher plate adjacent to the main housing, the pusher plate includingan inner section in contact with a second side of the firstpiezo-electric actuator, and an outer section spaced apart from the oneor more walls with a gap therebetween enabling a deflection of the firstvirtual button sufficient to activate the first piezo-electric actuator,while preventing damage to the first piezo-electric actuator when thepusher plate abuts the main housing.
 16. The mobile device according toclaim 15, further comprising a raised section extending outwardly fromthe pusher plate for engaging the first virtual button.
 17. The mobiledevice according to any one of claim 1, further comprising a pedestalextending from an inner wall of the first virtual button into contactwith the first piezo-electric actuator.
 18. The mobile device accordingto any one of claim 1, wherein the PCB is mounted against the firstpiezo-electric actuator, and configured to apply a preload force to thefirst piezo-electric actuator.
 19. The mobile device according to claim1, further comprising at least one flex PCB connector configured toconnect the first piezo-electric actuators to the controller.
 20. Themobile device according to any one of claim 2, wherein the outer framecomprises an original thickness of between 3 mm-6 mm; wherein the firstvirtual button comprises a thickness of between 1 mm to 2 mm; andwherein the first thinned section comprises a thickness of between 0.25mm to 0.75 mm.